Solenoid Valves and Their Importance in Refrigeration Systems October 2007
Overview Introduction Solenoid valves play an important role within refrigeration and air conditioning systems, controlling the flow of refrigerants. Though their base function turning the refrigerant flow on and off is quite simple, this function is key to ensuring system performance. Understanding how solenoid valves work increases the likelihood that contractors will install, remove and reinstall valves correctly, ensuring optimum system performance and protection. Contents This paper contains the following topics: Topic Page Basic operation of solenoid valves...1 Solenoid-valve types...2 Mechanical construction...4 Coils...5 Temperature ratings...6 Elastomers...8 Solenoid-valve applications...9 Maximum operating-pressure differential...12 Conclusion...12 About Emerson Climate Technologies...13 About the author of this paper...13
About Emerson Climate Technologies HVACR solutions leader Emerson Climate Technologies is the world s leading provider of heating, ventilation, air conditioning and refrigeration solutions for residential, industrial and commercial applications. Best-in-class technology is combined with proven engineering, design, distribution, educational and monitoring services to provide customized, integrated climate-control solutions for customers worldwide. Emerson Climate Technologies is committed to working with contractors and manufacturers to provide global solutions to improve human comfort, safeguard food and protect the environment. Emerson Climate Technologies Flow Controls division Emerson Climate Technologies Flow Controls division is the leading provider of precision mechanical and electromechanical controls for air conditioning and refrigeration systems. The group designs innovative refrigerant flow products, moisture indicators, filter driers and oil controls for the HVACR industry that make contractors jobs easier, saving them time and money. Emerson solenoid valves The Emerson solenoid-valve offering plays an important role in the performance of air conditioning and refrigeration systems. As part of Emerson s commitment to the industry, each valve undergoes stringent Emerson testing to ensure fail-safe operation. And, with the lowest external leak rates in the industry, Emerson solenoid valves ensure precise refrigerant flow, preventing system failures and aiding in environmental protection. More information For more information, visit Emersonflowcontrols.com. About the author of this paper Al Maier Al Maier is vice president of application engineering for Emerson Climate Technologies Flow Controls division, with more than 30 years of refrigeration systems and components design experience. He held several positions at Emerson Climate Technologies, Inc. (formerly Copeland Corporation), including director of application engineering, general manager and engineering manager of the condensing unit division. Al has an associate s degree in electronics technology from the Academy of Aeronautics and a bachelor of science degree in engineering from Long Island University. He is a member of ASHRAE (American Society of Heating, Refrigerating & Air Conditioning Engineers) and chairman of the engineering committee of ARI s (Air-Conditioning and Refrigeration Institute) valves and accessories section. 13
Maximum operating-pressure differential Introduction Solenoid valves are rated in terms of maximum operating-pressure differential (MOPD) against which the valves will open. Example With the solenoid valve closed against an inlet pressure of 250 poundsper-square-inch gauge (psig) and outlet pressure of 50 psig, the pressure differential is 250 minus 50, or 200 pounds per square inch (psi). Rating for proper operation The MOPD rating of the valve must be equal to or greater than 200 psi, if the valve is to open properly. Factors affecting rating The temperature of the coil windings and the actual applied voltage are prime factors affecting the MOPD rating. The MOPD is reduced as the coil temperature increases or the applied voltage is lowered. The MOPD ratings listed in solenoid manufacturers catalogs are determined by operating the valve with 85 percent of rated coil voltage applied to the coil after the solenoid coil has attained its maximum temperature under full rated voltage. Conclusion Solenoid valves in refrigeration systems Although the solenoid valve s primary function within refrigeration systems turning refrigerant flow on and off seems simple enough, this function can be quite complex and is essential in terms of ensuring correct installation, service and benefits. Ensuring correct installation and service Knowing how the solenoid valve works increases the likelihood that contractors will install the valves correctly and in a way that ensures optimum system performance. This information will also aid service technicians who may have to remove the valves to service the system, allowing them to correctly do so and then protect the system by correctly reinstalling the valves. Ensuring refrigerationsystem benefits The solenoid valve is a vital component in any refrigeration system. Knowing how it works helps to ensure system benefits, such as energy efficiency, leak prevention and overall system protection. 12
Basic operation of solenoid valves Definitions A solenoid is a simple form of an electromagnet consisting of a coil of insulated copper wire. A solenoid valve is an electromechanical valve frequently used to control the flow of liquid or gas. Function Solenoid valves are found in many applications and are commonly used in refrigeration and air conditioning systems. Their function is simply to turn refrigerant flow on and off. Benefits Solenoid valves offer fast and safe switching, reliability, long life and compact design. Operation A solenoid valve operates in the following way: Stage Description 1 When the solenoid coil is electrically energized, it produces a magnetic field that attracts iron and many of its alloys. 2 An iron armature or plunger (shown in Figure 1) is drawn up into the core of the solenoid. 3 A stem and pin or poppet attached to this plunger opens the valve port. 4 When the solenoid valve is de-energized, the plunger falls, and the poppet closes the valve port. Note: This magnetic principle constitutes the basis of design for all solenoid valves. Diagram of solenoid valve Figure 1 shows the parts of a solenoid valve. Figure 1 Role in system performance Because solenoid valves are electrically operated, their on-off function can be controlled automatically by suitable control systems. This function is extremely important, in terms of system performance. 1
Solenoid-valve types Introduction Solenoid valves can generally be divided into two types: Direct acting Pilot operated Direct-acting solenoid-valve operation In a direct-acting solenoid valve, the pull of the coil opens the valve port directly, by lifting the pin off the valve seat. Diagram of direct-acting solenoid valve Figure 2 shows the parts of a direct-acting solenoid valve. Figure 2 Direct Acting Top plug Enclosing tube Return spring Plunger Seal Pin Direct-acting port size limitation Because a direct-acting solenoid valve depends on the power of the coil for operation, its port size for a given operating-pressure differential is limited by the practical limitations of the coil size. Direct-acting solenoids are limited to smaller port sizes, below 1 /4-inch diameter. Pilot-operated solenoidvalve operation In a pilot-operated solenoid valve, the plunger does not open the main port directly. Instead, the following operation occurs: Stage Description 1 The plunger opens a pilot port. 2 Pressure on top of a piston is released through the pilot port, thus creating a pressure imbalance across the piston. 3 With the pressure underneath the piston now greater than the pressure on top, the piston will move in an upward direction, opening the main port. 4 When the plunger drops, it closes the pilot port; thus, the pressure above and below the piston equalizes, and the piston closes the main port. 5 The pressure difference across the valve, acting on the area of the main port, holds the piston in a tightly closed position. 2
Hot-gas bypass The compressor capacity can be reduced by bypassing the hot discharge gas through a solenoid directly to the suction line. A desuperheating valve must be used in this type of system, to prevent the compressor from overheating and tripping its internal protector. As shown in Figure 10, an alternate approach is to feed the discharge gas to the inlet of the evaporator. As the evaporator warms up, the thermostatic expansion valve (TXV) will respond by allowing more flow, thereby acting as a desuperheating valve. This approach is preferred, as it maintains good velocity through the evaporator and prevents oil logging. Figure 10 Hot-Gas-Bypass Capacity Control Hot-gas defrost When defrost is required, the solenoid in the hot-gas-bypass system opens. This allows discharge gas to go to the evaporator, thereby defrosting the coil (see Figure 11). A suction-stop solenoid is also needed in this system, to isolate the discharge from going right back to the compressor. Figure 11 Hot-Gas Defrost 11
Solenoid-valve applications (continued) Suction applications In a suction application, the solenoid valve provides complete isolation for temperature control and defrosting, or operates as a suction bypass on installations with two or more evaporators in a series fed by one expansion valve (see Figure 9). Figure 9 Suction-Stop Solenoid Valves Note: When used in suction applications, a valve with a low pressure drop should be used (less than two pounds-per-square-inch differential [psid]). Piston-type pilot valves often have a minopd that exceeds this. For this reason, diaphragm valves are recommended for suction service. Compressor unloading Solenoid valves can be used to unload compressors in a variety of ways. The most common method works as follows: Stage Description 1 A solenoid is employed to divert discharge pressure to a piston that, when activated, blocks the suction valve in an open position. 2 With the valve blocked open, no compression takes place in that cylinder. 3 This lack of compression results in a drop in capacity. 10
Diagram of pilot-operated solenoid valve Figure 3 shows the parts of a pilot-operated solenoid valve. Figure 3 Pilot Operated Top plug Enclosing tube Plunger Piston Pilot Main port Risk of oversized pilot-operated valve With a pilot-operated valve, there is a minimum operating-pressure differential (minopd) required for the piston to stay open. If the valve is oversized for the application, then the minopd may not be achieved, resulting in a valve that will not open or will fail to stay open. 3
Mechanical construction Introduction The basic principles of operation hold true for all refrigerant solenoid valves, although certain mechanical variations in construction can be found. Common variations Common examples of mechanical variations include: Short-stroke plungers: The plunger is rigidly connected to the valve needle or poppet. Long-stroke/lost-motion plungers: During opening the plunger imparts a hammer blow to the valve stem. Diaphragm valves: A diaphragm is used instead of a piston. Installation position Solenoid valves with a spring-loaded plunger or diaphragm may be installed in any position; however, older-style solenoid valves that utilize a plunger dependent on gravity to close must be installed with the plunger in an upright, vertical position. Normally closed or open solenoids The most common type of solenoid is the normally closed type. When the coil is energized, the valve opens. When power is removed, the valve closes. In a normally open solenoid, the valve closes when power is applied to the coil and opens when the coil is de-energized. 4
Solenoid-valve applications Introduction Solenoid valves are used for controlling refrigerants in liquid or suction lines or in hot-gas lines. Some common applications for solenoid valves are: Pump-down cycle Temperature control of separate units in a multiple system Suction applications Compressor unloading Hot-gas bypass Hot-gas defrost Pump-down cycle In the pump-down cycle application, the solenoid valve is installed in the main liquid line and wired so that it closes whenever the thermostat is satisfied. A low-pressure control valve allows the refrigerant in the evaporator to be pumped down (see Figure 7). Figure 7 Pump-Down Cycle Note: This type of cycle is ideal in systems with large charges, because it prevents the possibility of the compressor starting with a large amount of liquid in the evaporator. Temperature control of separate units in a multiple system Figure 8 illustrates how the temperature of a single unit in a multiple system can be controlled by a thermostat operating a solenoid valve in the liquid line to that unit. Figure 8 Multiple Systems Continued on next page 9
Elastomers Definition An elastomer, by American Society for Testing and Materials (ASTM) standards, is defined as a substance that can be stretched at room temperature to at least twice its original length and, after having been stretched and the stress removed, returns with force to approximately its original length in a short period of time. Use with solenoid valves Elastomers are used in solenoid valves for many different functions, including: O-rings Gaskets Piston rings Diaphragms Seats Refrigeration applications Elastomers used for refrigeration applications include neoprene and polytetrafluoroethylene (PTFE). A glass-filled PTFE (Rulon ) is also used in many instances in which a harder material is required. 8
Coils Description Coils used in refrigeration applications are usually encapsulated, providing better protection against environmental extremes and longer life. In this coil type, the magnet wire is wound in layers over a nylon bobbin. This assembly is then completely molded or cast over all exposed portions. The most common encapsulants used for coils are epoxy formulations. Advantages of encapsulation Advantages of encapsulated coils include: Outstanding dimensional stability Cleaner appearance Moisture resistance Abrasion resistance Shock resistance Electrical strength Thermal dissipation Life expectancy and temperature The life expectancy of a coil assembly is usually considered to be a function of temperature. If the coil is operated within its design limits, then it will provide many years of acceptable life. As a rule of thumb, for every 10 degrees Celsius operation above the limiting coil temperature, the life expectancy decreases by 50 percent. Caution: Remove power before disassembly Any coil that is energized when not assembled to a valve will draw high currents, consequently becoming very hot. Continued operation in this manner will cause the coil to fail in a short period of time; therefore, it is important for the service person to make certain that power is removed from the coil before disassembling the coil from its valve. Dual-frequency coils Coils can be wound to operate on dual frequency (50 to 60 Hertz [Hz]). If such a coil is operated on 50 Hz, it will draw more power than when used at 60 Hz. It will also generate more heat than if used at 60 Hz. 5
Temperature ratings Introduction Solenoid coils are classified by their insulating materials with regard to coil-temperature rise. The maximum permissible temperature that can be tolerated is limited by the type of insulation and materials used in the construction of the coil assembly. Temperature limitations of insulation classes There are three classes of insulation commonly used for refrigeration coils. These are referred to as Class F, H and N. The temperature limitations of these classes are set by various standards associations (UL, CSA, etc.) and are as follows: Table 1 Class Maximum temperature rise F C F 171 95 H 207 115 N 243 135 Safety warning: Hot coils Regardless of which class insulation is used, the surface of the coil can become too hot to be safely touched by hand, even though the temperature is within the design limits of the insulation system. For this reason, solenoid coils should be located to avoid accidental human contact. Other temperature factors Other factors that affect solenoid-coil temperature include voltage, ambient fluid temperature and frequency. These are depicted in the following diagrams. Effect of voltage Figure 4 shows the effect of voltage on solenoid-coil temperature. Figure 4 Effect of Voltage 110% rated voltage Rated voltage Temperature 85% rated voltage Time 6
Effect of temperature Figure 5 shows the effect of temperature on solenoid-coil temperature. Figure 5 Effect of Temperature 450 F 200 F Temperature 100 F Time Effect of frequency Figure 6 shows the effect of frequency on solenoid-coil temperature. Figure 6 Effect of Frequency 50 Hz 60 Hz Temperature Time 7
About Emerson Emerson (NYSE: EMR), based in St. Louis, is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Sales in fiscal 2006 were $20.1 billion. For more information, visit GoToEmerson.com. About Emerson Climate Technologies Emerson Climate Technologies, a business of Emerson, is the world s leading provider of heating, ventilation, air conditioning and refrigeration solutions for residential, industrial and commercial applications. The group combines best-in-class technology with proven engineering, design, distribution, educational and monitoring services to provide customized, integrated climate-control solutions for customers worldwide. Emerson Climate Technologies innovative solutions, which include industry-leading brands such as Copeland Scroll and White-Rodgers, improve human comfort, safeguard food and protect the environment. For more information, visit EmersonClimate.com. About Emerson Climate Technologies Flow Controls division Emerson Climate Technologies - Flow Controls division is a leading manufacturer of valves, controls and system protectors commonly applied in air conditioning and refrigeration systems worldwide. The company continues to pioneer the control of refrigerant flow through innovative, high performance components, such as thermostatic expansion valves and filter driers. Emerson Climate Technologies - Flow Controls division is headquartered in St. Louis. For more information, visit Emersonflowcontrols.com Emersonflowcontrols.com. 2007FC-23 R1 (10/07) Emerson and White-Rodgers are trademarks of Emerson Electric Co, or one of its affiliated companies. 2007 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.